Graco DURON Performance Max 395 Repair Manual
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Graco DURON Performance Max 395 Repair Manual

Graco DURON Performance Max 395 Repair Manual

Airless sprayers
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Repair
Performance Maxt 395/495/595
Airless Sprayers
3300 psi (227 bar, 22.7 MPa) Maximum Working Pressure
Sprayer
395
233980
495
233981
595
All models not available in all countries.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Related manuals
. . . . . . .
309709
. . . . . . .
309665
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
233982
234589
234590
. . . . . . .
309250
. . . . . . .
309055

Table of Contents

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4
6
7
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5
12
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13
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15
ECOPYRIGHT 2003, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
ti2399
233980
. . . . . . .
309639
. . . . . . .
309705
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309714
Rev. C
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16
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20
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22

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Summary of Contents for Graco DURON Performance Max 395

  • Page 1: Table Of Contents

    ....On/Off Switch Replacement ... . . GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 ECOPYRIGHT 2003, GRACO INC. Graco Inc. is registered to I.S. EN ISO 9001...
  • Page 2 The following Warnings are for the safe setup, use, grounding, maintenance and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure–specific risks. Refer back to these Warnings. Additional, product–specific warnings may be found throughout the body of this manual where applicable.
  • Page 3 Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer. D Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco replacement parts only. D Do not alter or modify equipment.

  • Page 4: Component Function And Identification

    Component Identification and Function ti2377a ti2399 Fig. 1 Motor DC motor, permanent magnet, totally enclosed, fan cooled Drive Assembly Transfers power from DC motor to displacement pump Displacement Pump Transfers fluid to be sprayed from source through spray gun Fluid Outlet Spray gun is connected here Prime Valve Used to prime and drain sprayer (also relieves fluid outlet pressure) when open...

  • Page 5: General Repair Information

    General Repair Information Pressure Relief Procedure 1. Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair proce- dures. These parts are not normally provided with WARNING replacement assemblies. INJECTION HAZARD WARNING System pressure must be manually relieved to prevent system from starting ELECTRIC SHOCK HAZARD or spraying accidentally.

  • Page 6: Grounding

    Grounding WARNING Your system must be grounded. Read Warnings, page 2. The sprayer requires: Fluid supply container: follow local codes. Grounded Outlets Solvent pails used when flushing: follow local code. Only use conductive metal pails, placed on grounded surface such as concrete. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts grounding continuity.

  • Page 7: Troubleshooting

    Troubleshooting Relieve pressure; page 5. MOTOR WON’T OPERATE TYPE OF PROBLEM WHAT TO CHECK WHAT TO DO If check is OK, go to next check When check is not OK refer to this column 1. Pressure control knob setting. Motor will not run 1.
  • Page 8 Troubleshooting MOTOR WON’T OPERATE (Continued) WHAT TO CHECK WHAT TO DO TYPE OF PROBLEM If check is OK, go to next check When check is not OK refer to this column Basic Electrical Problems 1. That motor leads are securely fastened and 1.
  • Page 9 Troubleshooting LOW OR FLUCTUATING OUTPUT WHAT TO CHECK WHAT TO DO TYPE OF PROBLEM If check is OK, go to next check When check is not OK refer to this column Low Output 1. For worn spray tip. 1. Follow Pressure Relief Procedure Warn- ing, then replace tip.
  • Page 10 Troubleshooting LOW OR FLUCTUATING OUTPUT WHAT TO CHECK WHAT TO DO TYPE OF PROBLEM If check is OK, go to next check When check is not OK refer to this column Motor runs and pump strokes 1. Paint supply. 1. Refill and reprime pump. 2.
  • Page 11 Troubleshooting MOTOR IS HOT AND RUNS INTERMITTENTLY WHAT TO CHECK WHAT TO DO TYPE OF PROBLEM If check is OK, go to next check When check is not OK refer to this column Motor is hot and runs intermit- 1. Determine if sprayer was operated at high 1.

  • Page 12: Spin Test

    Spin Test Setup Armature, Brushes, and Motor Wiring Open Circuit Test (Continuity) 1. Connect red and black motor leads with test lead. Electric Shock Hazard; page 5. Turn motor fan by hand at about two revolutions per second. 2. If uneven or no resistance, check for: broken brush To check armature, motor winding and brush electrical springs, brush leads, motor leads;...

  • Page 13: Motor Brush Replacement

    Motor Brush Replacement The 395/495/595 sprayer’s motors are supplied by two different motor manufacturers. Style A motor has brush caps held on with screws. Style B has brush caps that snap onto the motor. Determine which style motor you are servicing and refer to the appropriate illustration in the following instructions.
  • Page 14 Motor Brush Replacement Motor Brush Installation CAUTION When installing brushes, follow all steps carefully to avoid damaging parts. ti4195a ti4194a Style B Style A Fig. 7 1. Fig. 7. Install new brush (F) with lead into brush c. Turn sprayer ON. Slowly increase pressure holder (C).

  • Page 15: On/Off Switch Replacement

    On/Off Switch Replacement Removal Installation 1. Install new ON/OFF switch (58). Install locking ring Relieve pressure; page 5. and toggle boot (30). 2. Fig. 8. Remove four screws (12) and pressure control cover (50). 2. Connect two wires (A) to ON/OFF switch. 3.

  • Page 16: Pressure Control Repair

    Pressure Control Repair Motor Control Board Removal Installation 1. Clean pad on rear of motor control board. Apply Refer to Fig. 8. small amount of thermal compound 073019 to pad. 2. Fig. 8. Install motor control board (49) with six Relieve pressure;...
  • Page 17 Pressure Control Repair Digital Display Messages No display does not mean that sprayer is not pressurized. Relieve pressure before repair; page 5. DISPLAY INDICATION ACTION SPRAYER OPERATION No Display Loss of power Check power source. Relieve pres- Sprayer stops. Power is not applied. sure before repair or disassembly.
  • Page 18 Pressure Control Repair Pressure Control Transducer Pressure Adjust Potentiometer Removal Removal Refer to Fig. 8. Refer to Fig. 8. Relieve pressure; page 5. Relieve pressure; page 5. 2. Remove four screws (12) and cover (50). 2. Remove four screws (12) and cover (50). 3.

  • Page 19: Drive Housing Replacement

    Drive Housing Replacement 5. Remove two screws (12) and cover (22). CAUTION 6. Remove four front screws (47). Do not drop gear cluster (44) and (40) when remov- ing drive housing (42). Gear cluster may stay en- 7. Pull drive housing (42) off of motor (54). gaged in motor front end bell or drive housing.

  • Page 20: Motor Replacement

    Motor Replacement Disassembly 7. Remove two screws (47) and control housing (48). 8. Remove two screws (47) and manifold (15). Relieve pressure; page 5. 9. Remove four screws (47) and motor (54) from frame (59). 2. Remove pump (13); Displacement Pump Re- Assembly placement, page 21.

  • Page 21: Displacement Pump Replacement

    1. Fig. 13. Extend pump piston rod fully. Apply grease to top of pump rod at (A) or inside connecting rod. ti2568a Fig. 14 7. Fig. 15. Fill packing nut with Graco TSL until fluid flows onto top of seal. ti2568a ti2615a Fig.

  • Page 22: Technical Data

    39.5 (100.3) Handle up TO PLACE AN ORDER OR FOR SERVICE, contact your Graco distributor, or call 1–800–690–2894 to identify the nearest distributor. All written and visual data contained in this document reflects the latest product information available at the time of publication.

This manual is also suitable for:

Duron performance max 495Duron performance max 595

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